US9640449B2 - Automated inline inspection of wafer edge strain profiles using rapid photoreflectance spectroscopy - Google Patents
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Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L22/00—Testing or measuring during manufacture or treatment; Reliability measurements, i.e. testing of parts without further processing to modify the parts as such; Structural arrangements therefor
- H01L22/20—Sequence of activities consisting of a plurality of measurements, corrections, marking or sorting steps
- H01L22/24—Optical enhancement of defects or not directly visible states, e.g. selective electrolytic deposition, bubbles in liquids, light emission, colour change
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/16—Measuring arrangements characterised by the use of optical techniques for measuring the deformation in a solid, e.g. optical strain gauge
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/8806—Specially adapted optical and illumination features
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/95—Investigating the presence of flaws or contamination characterised by the material or shape of the object to be examined
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/95—Investigating the presence of flaws or contamination characterised by the material or shape of the object to be examined
- G01N21/9501—Semiconductor wafers
- G01N21/9503—Wafer edge inspection
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L22/00—Testing or measuring during manufacture or treatment; Reliability measurements, i.e. testing of parts without further processing to modify the parts as such; Structural arrangements therefor
- H01L22/10—Measuring as part of the manufacturing process
- H01L22/12—Measuring as part of the manufacturing process for structural parameters, e.g. thickness, line width, refractive index, temperature, warp, bond strength, defects, optical inspection, electrical measurement of structural dimensions, metallurgic measurement of diffusions
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/17—Systems in which incident light is modified in accordance with the properties of the material investigated
- G01N21/1717—Systems in which incident light is modified in accordance with the properties of the material investigated with a modulation of one or more physical properties of the sample during the optical investigation, e.g. electro-reflectance
- G01N2021/1725—Modulation of properties by light, e.g. photoreflectance
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2201/00—Features of devices classified in G01N21/00
- G01N2201/06—Illumination; Optics
- G01N2201/061—Sources
- G01N2201/06113—Coherent sources; lasers
Definitions
- the present invention is directed generally toward photoreflectance (PR), and more particularly to PR for strain measurement in silicon wafers.
- Photoreflectance (PR) and piezoreflectance (PzR) of substrates such as silicon-germanium (SiGe), gallium arsenide (GaAs), indium gallium sulfate (InGaS) exhibit a typical band gap of approximately 1.5 eV or 3.5 eV.
- Rapid PR (RPR) spectroscopy requires the simultaneous detection of a small modulated reflectance ( ⁇ R) signal and a large time-invariant, unmodulated reflectance signal R, and the relation of the small modulated reflectance and unmodulated reflectance ( ⁇ R/R). Even at parts of the spectrum where it is significant, ⁇ R is relatively small compared to the unmodulated reflectance R, of the order of several to hundreds parts per million. Various sources of optical and electrical noises will be present and these dominate the ⁇ R signal. However, the ⁇ R signal is always present at the known modulation frequency and so methods of frequency-discriminating signal recovery are typically employed to detect a signal at this known frequency.
- phase sensitive lock-in amplification was required for the measurement of the ⁇ R signal in PR spectroscopy and the measurement was to be made at different times for each wavelength, so that the ⁇ R/R spectrum was therefore generally recorded in a serial spectral mode. This limits the practical speed of the PR measurement and precludes its widespread industrial application in high-speed production line inspection of semiconductor wafers.
- Strained silicon refers to silicon in which strain is engineered locally in a device structure or globally across a wafer by a local or global stress to accelerate electrons, which allows manufacture of faster devices.
- sSi transistors due to increased electron mobility and velocity have already been proven.
- the technology of strain engineering is being widely used to speed carrier mobility in transistor channels in order to increase the drive currents.
- Globally sSi on a wafer comprises a very thin layer of single-crystal silicon strained by pseudomorphic growth up to a critical thickness on a relaxed Si x Ge 1-x stressing layer of wider lattice constant dependent on the Ge mole fraction x.
- the strain in the silicon is described as biaxial, the result of two effects, namely, the expansion of the silicon lattice due to the wider lattice constant of the relaxed Si 1-x Ge x layer, which is tensile stressing it, and the contraction of the silicon lattice in the vertical direction because of its behavior as a near-perfect Poisson solid.
- These two strain effects, hydrostatic tension, and uniaxial compression will be presently shown to be mirrored by two competing effects in the electronic band structure in the vicinity of the E 1 critical point of silicon, whose combined effect is measurable by PR spectroscopy.
- Such a sSi layer can be transferred onto an SiO 2 buried oxide layer while retaining the strain to form a strained silicon-on-insulator (SSOI) wafer.
- X-ray diffractometry X-ray diffractometry
- RS Raman spectroscopy
- Other optical inspection techniques look for slip-lines on the surface or cracks in the edge of silicon wafers. Optical inspection methods detect defects rather than measuring strain and are therefore unsuitable for identifying problems before defects occur, controlling strain sources, relating strain defects to specific process parameters, or managing strain levels in wafers.
- the present invention is directed to a novel method and apparatus for directly measuring strain in a wafer production process in time to apply the measurements to prevent defects.
- PR spectroscopy is used to measure strain at or near the edge of a wafer in a production process.
- the strain measurement is used to anticipate defects and make prospective corrections in later stages of the production process.
- strain measurements are used to associate various production steps with defects to enhance later production processes.
- FIG. 1 shows a block diagram of a system according to one embodiment of the present invention for implementing RPR in a wafer fabrication process for edge strain measurement;
- FIG. 2 shows an environmental representation of one embodiment of the present invention
- FIG. 3 shows an environmental representation of one embodiment of the present invention
- FIG. 4 shows a block diagram for a computer system according to one embodiment of the present invention
- FIG. 5 shows a flowchart of a method for edge strain measurement
- FIG. 6 shows optical elements in an embodiment of the present invention
- FIG. 7 shows a block diagram according to another embodiment of the present invention for implementing RPR in a wafer fabrication process.
- PR spectroscopy provides a useful alternative to XRD and RS to meet the requirements for a nondestructive in-line strain metrology tool.
- Rapid PR and specifically micro RPR ( ⁇ RPR)
- ⁇ RPR micro RPR
- Embodiments of the present invention measure local wafer strain and local/global strain profiles on and near the edge of a silicon wafer based on ⁇ RPR methods. Such measurements allow for monitoring and management of the resulting impact of wafer edge strain on process yield and health.
- Rapid thermal processing (RTP) of silicon wafers can lead to various forms of residual strain in the wafers.
- the silicon wafer and wafer carrier heat-up and cool-down at different rates.
- the contact points between the silicon wafer and the wafer carrier can cause a local thermal gradient in the wafer that results in a corresponding thermally induced local residual strain that remains after the wafer cooled.
- the residual strain is local and on a microscopic scale can exceed the yield strength of silicon. This may result in lattice defects such as slip dislocations and micro-cracks. These defects are undesirable both in terms of device yield and process health.
- Slip dislocations may induce slip line defects in surface films that propagate with further processing and compromise yield.
- Micro-cracks can lead to wafer breakage during further processing that can damage expensive processing equipment and reduce process throughput.
- Measurement of wafer strain at/near the wafer edge provides insight into the status of a wafer's slip dislocations or susceptibility to developing slip dislocations, strain-related micro-cracking or susceptibility to developing micro-cracks, and susceptibility to strain-related wafer breakage.
- a probe light source 101 generates an incident probe beam and directs the incident beam through optical components 102 , including fiber optics, onto an edge of a sample 104 .
- the incident light passes through an incident filter 116 to deliver a blue ultraviolet (UV) beam to the edge of the sample 104 .
- a perturbation is optically applied to the edge of the sample 104 by a modulated pump beam.
- the modulated pump beam is produced by a pump laser 110 , with the pump laser 110 beam passing through a modulator 112 , such as a mechanical chopper, and modulated pump beam optical components 114 to the edge of the sample 104 .
- the modulated pump beam may be filtered by a pump beam filter 118 to a desirable frequency range.
- the reflectance of the edge of the sample 104 is altered by photoinjection of charge carriers via the interaction of the incident beam and modulated pump beam.
- the modulated reflected incident beam may pass through a spectrograph filter 106 to filter the modulated reflected incident beam to a bandpass region of the spectrum in the region of the E 1 transition of silicon at approximately 3.4 eV.
- the modulated reflected incident beam is transmitted through receiving optical components 120 and dispersed into its constituent wavelengths by a spectrograph 108 and the constituent components are sampled by a detector 122 .
- a processor 124 connected to the detector 122 analyzes the spectrographic data to measure wafer strain in-line in sSi wafers including SSOI and silicon-germanium on insulator by measuring the direct bandgap energy of the sSi layer and converting the value to strain using a theoretical model.
- the processor 124 reads the modulated reflectance ⁇ R signal as well as the unmodulated reflectance R signal from each pixel of the detector 122 in sufficiently rapid succession such that multiple measurements of the ⁇ R signal can be made within a single period of the modulation cycle.
- the acquisition time for the entire spectrum is approximately 1-2 ms (e.g., 1.03 ms). Depending on the measured structures, the acquisition may be averaged a plurality of times in order to improve the signal to noise ratio.
- the RPR spectrum model may be defined by:
- ⁇ E ⁇ square root over (1 ⁇ 3) ⁇ D 1 1 ( ⁇ ⁇ +2 E ⁇ ) ⁇ square root over (2 ⁇ 3) ⁇ D 3 3 ( ⁇ ⁇ +E ⁇ )
- ⁇ sign implies addition to obtain the shift in the HH and LH branches
- ⁇ ⁇ is strain perpendicular to growth
- ⁇ ⁇ is strain in-plane
- D 1 1 is the hydrostatic deformation potential, measured by Kondo and Moritani as ⁇ 9.8 eV
- D 3 3 is the intraband strain deformation parameter along the direction perpendicular to growth, having a value of 4.7 eV.
- strain tensor elements perpendicular to growth take the form:
- RPR results may be compared to RS. Actual calibration against a range of RS values gives a calibration result of 3.399 and ⁇ 0.1368 eV as unstrained silicon bandgap and conversion factor, respectively.
- PR techniques may be used to measure tensile in-plane edge strain in biaxially strained SSOI wafers.
- a decrease in the acquisition time by a factor of 100 to 500 may be achieved for a nondestructive technique suitable for in-line sSi metrology.
- a decrease and split (E LH and E HH ) in the silicon bandgap have been observed upon tensile strain. Based on theoretical models, the E LH transition value may be converted to biaxial tensile strain, which is consistent with RS results.
- strain measurements taken at or near the edge of a wafer 224 are made with an optical scanning system 200 as described herein.
- the optical axis 206 of the optical scanning system 200 is maintained substantially normal to the portion of the surface of the wafer 202 where the measurement is made.
- the portion of the surface of the wafer 204 where the measurement is made is maintained substantially at the optimal focus position of the optical scanning system 200 throughout the entire trajectory 202 traveled by the optical scanning system 200 . It is noted that maintain optimal (or adequate) focus may be accomplished using the optically measured wafer edge profiles for feed-forward to wafer r and z stages or any other metrics necessary to maintain focus and normality of the optical axis 206 even where the edge is irregular.
- the feed-forward procedure may be combined with a real-time auto-focus mechanism to mitigate errors in the measurement of the wafer 204 edge profile.
- the feed-forward procedure may be replaced with a combined real-time auto-focus mechanism and default wafer profile.
- a semi-circle or other pattern may be used for the wafer edge profile.
- a wafer 304 in a production process may be inspected by various inspection modules 300 , 306 .
- module 300 includes an edge inspection module.
- module 306 includes a ⁇ RPR edge strain measurement module 306 .
- the ⁇ RPR strain measurement module 306 may measure strain at sample spot sizes 302 of several millimeters down to less than 10 micro-meters.
- the ⁇ RPR strain measurement module 306 may sample wafer 304 edge locations as the wafer 304 moves.
- the ⁇ RPR strain measurement module 306 may take measurements in a continuous fashion, repeatedly, over a track defined by an edge profile.
- the ⁇ RPR edge strain measurement module 306 may include a time-delay integration (TDI) sensor for performing the actual image collection. Furthermore, because the ⁇ RPR strain measurement module 306 collects both modulated and unmodulated light reflected from the wafer 304 , a modulating pump beam source may be periodically turned on and off to modulate an incident beam at a given sampling rate.
- TDI time-delay integration
- the ⁇ RPR optics head may provide for multiple simultaneous measurement points as a means to increase throughput and mitigate laser damage.
- the ⁇ RPR optics head may be on a dedicated wafer inspection system, or may be integrated into a wafer inspection platform with multiple inspection systems.
- the ⁇ RPR may be mounted such that a step-wise or continuous measurement is made of a specific zone circumference of the wafer.
- the computer system 400 includes a processor 422 , memory 404 connected to the processor 422 for storing computer executable code, and a data storage element 406 for storing wafer profile data.
- a spectral detector 424 such as a TDI sensor, is connected to the processor 422 to receive reflected light from the edge of a wafer and modulated reflected light from the edge of the wafer via a spectrograph.
- an illumination device may provide an incident beam arranged to illuminate a portion of the wafer. The incident beam is then reflected to a spectrograph for detection by the spectral detector 424 .
- the illumination device may also include a pump laser to produce a modulation beam that illuminates the portion of the wafer to produce a modulated incident beam reflected to the spectrograph for detection by the spectral detector 424 .
- the processor 422 receives spectral data and produces a strain measurement associated with the illuminated portion of the wafer, the illuminated portion being a surface on the or about the edge of the wafer.
- the processor 422 may adjust the location and orientation of the spectral detector 424 based on an edge profile stored in the data storage element 406 , or a predetermined spot locations where strain measurements are desirable. Based on the strain measurements, the processor 422 may determine that a defect is likely in the production process or that a strain threshold for a portion of the wafer has been reached. Furthermore, given known production process parameters, the processor 422 may determine that strain related defects in the edge of a wafer may be correlated to such parameters; for example, temperature disparities during the production process.
- Local and global strain profiles on or near a wafer edge may allow the processor 422 to identify problematic stain profiles before defects or micro-cracks appear, or at least identify wafers that may already have developed strain-related defects; control strain-related defects such as slip lines and micro-cracks at or near the edge of the wafer; identify and control strain sources; and manage strain level in wafers.
- Multiple ⁇ RPR strain measurements can be made on a wafer in a stepwise or continuous fashion about the circumference of the wafer. For example, measurements may be made of a top edge surface, bottom edge surface, and side surface of an edge of the wafer, and may incorporate care areas and/or exclusion zones for the measurement. Multiple ⁇ RPR strain measurements may be post-processed to generate a continuous strain profile at virtually any scale; e.g. globally such as around the circumference of the top edge, side edge, and bottom edge of the wafer down to a local region whose smallest size is limited by the sample spot size.
- a flowchart depicting a method for edge strain measurement is shown.
- a wafer e.g., silicon wafer
- the production apparatus may include, but is not limited to, an embodiment of the present disclosure.
- the wafer is aligned for edge inspection.
- the wafer production apparatus measures 504 an edge profile of the wafer.
- the wafer production apparatus performs a strain measurement on an edge surface of the wafer.
- the measurements may include, but are not limited to, spot measurements or continuous measurements.
- the wafer production apparatus may track multiple parameters when performing the strain measurements; such parameters may include identifying particular areas of interest for spot measurement, particular areas identified via previous production processes that are prone to strain related defects, monitoring strain values for a pre-determined threshold, or SNR parameters.
- the wafer production apparatus may modifies a feature of the wafer production process based on the edge strain measurements.
- Embodiments of the present disclosure may have an edge strain measurement resolution of better than 0.1%, a silicon yield stress of approximately 1 GPa at room temperature and approximately 10 GPa at 1000° C., and a Young's modulus of approximately 130.
- the edge of a spinning wafer 622 in a wafer production process is illuminated.
- a white probe light may illuminate the wafer and scan the wafer along a selected spatial scan direction.
- the reflected illuminated light may be collimated by a first curved mirror 602 and reflected onto a diffraction grating 604 .
- the diffraction grating 604 reflects a diffracted image from the edge of the spinning wafer 622 to a second curved mirror 606 that focuses the diffracted image onto a TDI sensor 608 . As shown in FIG.
- light received by the TDI sensor 608 may be across the sensor as a function of wavelength, with the scanning direction being arranged orthogonal to this direction.
- data from the TDI sensor 608 is used to determine a strain measurement associated with the edge of the spinning wafer 622 .
- a reference beam 700 such as a reference laser beam (e.g., reference laser suitable for AF)
- a pump beam 710 passes through the same optical elements 702 , 704 , 706 , 708 , 712 to the same spot on the edge of the wafer 722 .
- optical element 708 includes one or more prisms 708 (e.g., beam separation prism) for directing the reference beam 700 and pump beam 710 along a common entrance path.
- optical element 712 includes a first beam splitter 712 (e.g., polarized beam splitter or GLAN-type beam splitter) for reflecting the reference beam 700 and pump beam 710 to a first mirror 702 .
- the first mirror 702 may be, but is not required to be, a convex mirror for reflecting the reference beam 700 and pump beam 710 to a second mirror 704 and third mirror 706 respectively.
- the second mirror 704 and third mirror 706 may be, but are not required to be, concave mirrors for focusing the reference beam 700 and pump beam 710 to a particular portion of the edge of the wafer 722 .
- the second mirror 704 and third mirror 706 may be arranged so as to focus the reference beam 700 and pump beam 710 onto the wafer 722 from different angles.
- a P-wave illuminator 714 may introduce a probe beam to a second beam splitter 716 (e.g., 50 / 50 beam splitter), which directs a portion of the probe beam through one or more optical elements 702 , 704 , 706 , 712 to combine with the reference beam 700 and pump beam 710 .
- a second beam splitter 716 e.g., 50 / 50 beam splitter
- light reflected from the wafer 722 traverses one or more of the optical elements 702 , 704 , 706 through the first beam splitter 712 and the second beam splitter 716 to a detector 724 .
- a slit diffraction element 718 e.g., slight has long width aligned with TDI
- a band-pass filter 720 may be interposed between the second beam splitter 716 and the TDI detector 724 .
- Embodiments of the present invention provide a means to measure and control wafer edge strain, in-line, before associated defects and adverse consequences occur as described.
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Abstract
Description
ΔE=√{square root over (⅓)}D 1 1(ε⊥+2E ∥)±√{square root over (⅔)}D 3 3(ε⊥ +E ∥)
where the ± sign implies addition to obtain the shift in the HH and LH branches, ε⊥ is strain perpendicular to growth, ε∥ is strain in-plane, D1 1 is the hydrostatic deformation potential, measured by Kondo and Moritani as −9.8 eV, and D3 3 is the intraband strain deformation parameter along the direction perpendicular to growth, having a value of 4.7 eV. The relationship may therefore be rewritten as:
ΔE=−5.658(ε⊥+2ε∥)±3.837(ε⊥+ε∥)
where x is the germanium concentration, C11 and C12 are the elastic constants, and the Bir-Pikus Hamiltonian for a G1 type band having the form:
a 0(Si1-xGex)=a 0(Si)+0.200326x(1−x)+[a 0(Ge)−a 0(Si)]x 2
Therefore the lower energy branch of the split transition shifts according to:
ΔE=E LH−3.4=−0.1375ε∥(eV)
where E∥ is expressed in percentage strain. As a result, the strain value is calculated using the bandgap shift of the ELH transition compared to the unstrained silicon direct bandgap 3.4 eV. It is conventional to quote the tensile strain in the plane of the wafer.
Claims (21)
Priority Applications (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US14/688,739 US9640449B2 (en) | 2014-04-21 | 2015-04-16 | Automated inline inspection of wafer edge strain profiles using rapid photoreflectance spectroscopy |
| PCT/US2015/026775 WO2015164309A1 (en) | 2014-04-21 | 2015-04-21 | Automated inline inspection of wafer edge strain profiles using rapid photoreflectance spectroscopy |
| DE112015001898.0T DE112015001898T5 (en) | 2014-04-21 | 2015-04-21 | Automated inspection during the production process of profiles of wafer edge deformation using fast photoreflective spectroscopy |
| TW104112765A TWI636242B (en) | 2014-04-21 | 2015-04-21 | Automated inline inspection of wafer edge strain profiles using rapid photoreflectance spectroscopy |
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| US14/688,739 US9640449B2 (en) | 2014-04-21 | 2015-04-16 | Automated inline inspection of wafer edge strain profiles using rapid photoreflectance spectroscopy |
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| US20230003637A1 (en) * | 2019-12-11 | 2023-01-05 | Nova Ltd. | Method and system for broadband photoreflectance spectroscopy |
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| US10564126B2 (en) * | 2015-12-03 | 2020-02-18 | Hamamatsu Photonics K.K. | Optical polarization inspection device and method |
| US10976284B2 (en) | 2015-12-03 | 2021-04-13 | Hamamatsu Photonics K.K. | Inspection device and inspection method |
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Also Published As
| Publication number | Publication date |
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| WO2015164309A1 (en) | 2015-10-29 |
| US20150371910A1 (en) | 2015-12-24 |
| DE112015001898T5 (en) | 2017-02-02 |
| TW201546431A (en) | 2015-12-16 |
| TWI636242B (en) | 2018-09-21 |
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